Method of forming solderless electrical conductor connections



Jan. 22, 1946. w, T. EPPLER ETAL 2,393,355

METHODS FORMING SOLDERLESS ELECTRICAL CONDUCTOR CONNECTIONS Filed Oct.10.

P tented Jan. 22, 1946 UNITED s'rAr as PATENT OFFICE m rror) or somesomlinmssmormoAL commc'ron commons Walter T. Eppler, Cranfo rd, andBarry L. Hus-- son, Westfield, N. J., assignors to Western ElectricCompany, Incorporated, New York, N. Y., a corporation of New York -f. I

Application October 10, 1942, Serial No. 461,510 2 Claims. (Cl. 29-1411)This invention relates to methods of forming solderless electricalconductor connections.

An object or the invention is to provide an 7 efficient and effectivemethod of forming solderless electrical conductor connections whereby a;moistureproof, mechanically strong connection of low contact resistanceis provided.

In accordance with one embodiment of the invention as applied to thejoining of conductors to terminals of telephone apparatus, a hookeduninsulated end portion of a conductor is interlocked in an aperture ofa terminal. Thereafter,

, a sleeve of relatively soft metal previously threadwill be apparentfrom the following detailed de-.

scription taken in conjunction with theaccompanying drawing, inwhioh:

Fig. 1 is .a side elevation the terminal;

Fig. 2 is a plan view of the parts shown in Fig. 1 after the terminaland conductor end have been onto the conductor ll position over the theterminal prior to the interlocking oi the terminal l0 and the hookedconductor portion ii. The sleeve 'll may be'made of lead, lead alloy orother suitable and relatively easily compressible metal and is formedwith an opening ll of such diameter to permit it to be freely positionedon the terminal and movable therealong and over the overlapping andinterlocked portions of the terminal and conductor to the position shownin broken outline in Fig. 2. In this position of the sleeve, it is readyto be compressed to complete the connection.

Although the sleeve I4 is shown as cylindrical, an oval or partiallyflattened sleeve may also be used. Furthermore, instead of positioningthe sleeve ll upon the terminal l0, it may be threaded prior to itsmovement into interlocked portion of the terminal and conductor. In somecases, the ter ininai Ill, instead 01 being flat, may be round or takeanother form.

v of a. terminal and a hooked uninsulated end of a conductor in spacedrelation and a compressible sleeve threaded onto interlocked, the-sleevebeing shown in its initial position and in broken outline in positioncover- 11118 the interlocked terminal and conductor porons;

Fig. 3 is a vertical sectiontaken on the'line 3-4 of Fig. 2;

Fig. 4 is a view similar to Fig. 2 after the sleeve has been compressed;

Fig. 5 is a vertical section taken on line-- 5-! of Fig. 4; and I Fig. 6is a vertical section taken on the line t-s or Fig. 5.

Referring to the drawing in detail, and particularly to Fig. 1, wherein,in one application of the invention, a flat electrical conductorterminal is indicated iragmentarily at l0, which is provided at itsouter end with an aperture II for receiving in interlocked relation ahooked portion I2 01 an uninsulated end 0!. an insulated wire orconductor l3, shown spaced from the terminal preparatory to beinginterlocked therewith. Surrounding the terminal I0 is a cylindricalsleeve, collar or tube M (Fig. 3), which is threaded onto or its walltaken with its outer and For the purpose of compressing the sleeve l4and causing the metal thereof to-cold flow to the Iorm shown in Figs.pressure by Jaws of pliers or other suitable tools (not shown) in whichthe opposed faces 01 coopcrating Jaws or dies are suitably shapedtodeform the sleeve to the form shown. Upon completion or the sleevecompressing and deforming operation, as will be observed by referring toFigs. 4, 5and 6, the metal of the sleeve has cold flowed to fill allgroovesor holes and completely surrounds the overlapping minal andconductor. Thus, a moistureprooi, mechanically strong solderlessconnection is provided tor the terminal l0 and conductor is and onewhich is or very low contact resistance. The mass or metal injthe sleevel4 and the thickness inner-dimensions, it will be understood, are suchthat the desired result is obtained in subjecting it to compression inthe manner above described.

From the above description of the invention, it will be evident that inits application to the forming or electrical connections, it ispracticable,

4, 5 and 6, it 18.8llbil6ct6d t0 interlocked portions-of the terend ofsaid other conductor and engaging it in said conductor aperture, placinga metallic sleeve over the interlocked conductor portions, andcompressing the sleeve upon its entire outer peripheral surface toretain the conductors in interlocked relation.

2. The method of attaching a single electrical conductor of circularcross-section to a flat con- .ductor strip which comprises forming anaperture in said conductor strip, forming a, hook on an end of saidsingle conductor and entering said hooked end or said single conductorin said aper- 7 9,398,855 one of saidv conductors, forming a hook on angrooves or holes thereat and providing apmoistureproof, mechanicallystrong connection of low contact resistance.

WALTER. T. EPPLER. HARRY L. HUBSON'.

